Power tool housings

ABSTRACT

A power tool is provided that, in one version, includes a front housing that supports an output drive, and a back cap located opposite the front housing. The back cap receives at least one fastener of the plurality of fasteners. A motor housing supports a motor and is located between the front housing and the back cap. The motor includes a rotor that is configured to rotate about a motor axis to drive rotation of the output drive. The fastener is disposed through the back cap, and secures to the front housing coupling the front housing, the motor housing, and the back cap together.

RELATED APPLICATION

The present application is a continuation under 35 U.S.C. § 120 of U.S.patent application Ser. No. 15/172,214, filed Jun. 3, 2016, entitled“Power Tool Housings,” which claims priority to U.S. Provisional PatentApplication, Ser. No. 62/171,768, filed on Jun. 5, 2015, entitled “PowerTool Housings.” The present application is also a continuation ofInternational Application No. PCT/US16/35674, filed on Jun. 3, 2016,entitled “Power Tool Housings.” The subject matter disclosed in U.S.patent application Ser. No. 15/172,214, U.S. Provisional PatentApplication Ser. No. 62/171,768, and International Application No.PCT/US16/35674 is hereby expressly incorporated into the presentapplication.

TECHNICAL FIELD AND SUMMARY

The present disclosure relates, generally, to housings for power toolsand, more particularly, to housings for cordless power tools, such ascordless impact tools.

Existing housings for power tools are typically sized to accommodatemotor housings of motors included in the power tools. For example, somepower tool housings may include two halves, sometimes referred to as“clam shells,” which are secured together to hold the motor housing ofthe motor within the halves of the power tool housings. In sucharrangements, the additional space occupied by the fasteners used tosecure the halves of the power tool housings together may cause the sizeof the power tool housings to be undesirable in certain applications.Accordingly, the present disclosure relates to a power tools having areduced size.

To that end, an illustrative embodiment of the present disclosureprovides a power tool which comprises a front housing, a plurality offasteners, a back cap, a motor, and a motor housing. The front housingsupports an output drive, and the back cap located opposite the fronthousing. The back cap includes a plurality of apertures each sized toreceive one fastener of the plurality of fasteners. The motor housingsupports a motor and is located between the front housing and the backcap. The motor includes a rotor that is configured to rotate about amotor axis to drive rotation of the output drive. The at least onefastener of the plurality of fasteners engages the back cap and isdisposed in at least one of the plurality of apertures of the back cap.The motor housing includes a plurality of grooves that extendsubstantially parallel to the motor axis. One groove of the plurality ofgrooves is aligned with one aperture of the plurality of apertures ofthe back cap. Each fastener of the plurality of fasteners is disposedthrough one of the plurality of apertures of the back cap, along onegroove of the plurality of grooves of the motor housing, and secures tothe front housing coupling the front housing, the motor housing, and theback cap together. Lastly, the plurality of fasteners extendssubstantially parallel to the motor axis when coupling the fronthousing, the motor housing, and the back cap together.

In the above and other embodiments of the present disclosure may alsocomprise: the front housing including a plurality of threaded recesses,wherein each threaded recess being aligned with one grove of theplurality of grooves in the motor housing and each threaded recess beingconfigured to receive one fastener of the plurality of fasteners; a bodythat wraps around at least a portion of the motor housing between thefront housing and the end cap; the body defining an interior space inwhich the motor housing is positioned and through which the plurality offasteners extend when the front housing, the motor housing, and the backcap are coupled together; the body further including at least two bodyparts wherein each of the body parts wrap around at least a portion ofthe motor housing between the front housing and the end cap; at leastone of the at least two body parts includes a flange that engages thefront housing; and at least one of the at least two body parts includesa flange that engages the back cap.

Another illustrative embodiment of the present disclosure provides apower tool that also comprises a front housing, a plurality offasteners, a back cap, a motor, and a motor housing. The front housingsupports an output drive, and the back cap is located opposite the fronthousing. The motor housing supports a motor and is located between thefront housing and the back cap. The motor includes a rotor configured torotate about a motor axis to drive rotation of the output drive. Atleast one fastener of the plurality of fasteners engages the back capand secures the motor housing to the front housing. The plurality offasteners also extends substantially parallel to the motor axis whencoupling the front housing, the motor housing, and the back captogether.

In the above and other embodiments of the present disclosure may alsocomprise: a body that wraps around at least a portion of the motorhousing between the front housing and the end cap; the body defines aninterior space in which the motor housing is positioned when the fronthousing, the motor housing, and the back cap are coupled together; thebody further including at least two body parts wherein each of the bodyparts wraps around at least a portion of the motor housing between thefront housing and the end cap; at least one of the at least two bodyparts includes a tab that engages the front housing; and at least one ofthe at least two body parts includes a tab that engages the back cap.

Another illustrative embodiment of the present disclosure provides apower tool that comprises a front housing, an output drive, a back cap,a motor housing, a motor, and a plurality of fasteners. The fronthousing supports the output drive. The back cap is located opposite thefront housing. The motor housing supports the motor. The motor includesa rotor configured to rotate about a motor axis to drive rotation of theoutput drive. The plurality of fasteners extends parallel to the motoraxis, each of the plurality of fasteners engage the front housing andthe motor housing, and the plurality of fasteners extends substantiallyparallel to the motor axis when coupling the front housing and the motorhousing together.

In the above and other embodiments of the present disclosure may alsocomprise: a back cap that includes a plurality of apertures each sizedto receive one fastener of the plurality of fasteners; the motor housingbeing located between the front housing and the back cap; the motorhousing includes a plurality of grooves that extends substantiallyparallel to the motor axis, and wherein one groove of the plurality ofgrooves is aligned with one aperture of a plurality of aperturesdisposed in the back cap; each fastener of the plurality of fasteners isdisposed through one of a plurality of apertures disposed in the backcap, along one groove of a plurality of grooves on the motor housing,and secures to the front housing to couple the front housing, the motorhousing, and the back cap together; a body that wraps around at least aportion of the motor housing adjacent the front housing, wherein thebody defines an interior space in which the motor housing is positionedwhen the front housing and the motor housing are coupled together, andwherein the body is selected from the group consisting of at least onebody part and a plurality of body parts; and the body including at leastone tab that engages the front housing.

BRIEF DESCRIPTION OF THE DRAWINGS

The concepts described in the present disclosure are illustrated by wayof example and not by way of limitation in the accompanying figures. Forsimplicity and clarity of illustration, elements illustrated in thefigures are not necessarily drawn to scale. For example, the dimensionsof some elements may be exaggerated relative to other elements forclarity. Further, where considered appropriate, reference labels may berepeated among the figures to indicate corresponding or analogouselements.

FIG. 1 is an exploded perspective view of various components held by ahousing of a PRIOR ART power tool;

FIG. 2 is a perspective view of a portion of an illustrative power toolaccording to the present disclosure;

FIG. 3 is a detailed perspective view of an interface between componentsof a tool housing of the power tool of FIG. 2 ;

FIG. 4 is another detailed perspective view of an interface betweenother components of the tool housing of the power tool of FIG. 2 ;

FIG. 5 is a sectional view taken about line 5-5 of FIG. 4 ; and

FIG. 6 is a cross-sectional side view of a portion of the power tool ofFIG. 2 .

DETAILED DESCRIPTION OF THE DRAWINGS

While the concepts of the present disclosure are susceptible to variousmodifications and alternative forms, specific exemplary embodimentsthereof have been shown by way of example in the drawings and willherein be described in detail. It should be understood, however, thatthere is no intent to limit the concepts of the present disclosure tothe particular forms disclosed, but on the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the present disclosure.

Referring now to FIG. 1 , a PRIOR ART power tool 10 is shown. The powertool 10 includes a power tool housing 12 that has a “clam-shell”construction, meaning that internal components of the power tool 10,such as the motor 18 and the motor housing 20, are held by two halves or“clam shells” 14, 16 of the housing 12 which are secured together (alongwith other housing components) to form the housing 12. This “clam shell”housing 12 is generally divided along a parting plane that passesthrough both the handle 28 of the power tool 10 and the axis about whichthe rotor of the motor 18 rotates during operation (which, in thisembodiment, is also the axis about which components of an impactmechanism 30 of the power tool 10 rotate during operation). Componentsof the motor housing 20 are secured together separately from the halves14, 16 to form the housing 20 that contains the motor 18.

The halves 14, 16 of the housing 12 are configured to receive fasteners22 to secure the halves 14, 16 together as shown in PRIOR ART FIG. 1 .Specifically, the half 14 is formed to include apertures 24, and thehalf 16 is formed to include apertures 26. During assembly of the tool10, the halves 14, 16 are aligned to permit the fasteners 22 to bereceived by corresponding apertures 24, 26 of the halves 14, 16. Assuch, the fasteners 22 extend in a direction indicated by arrow A thatis substantially perpendicular to a direction indicated by arrow B inwhich the motor 18 and the motor housing 20 extend (the arrow B beinggenerally parallel to the axis about which both the rotor of the motor18 and the components of the impact mechanism 30 rotate duringoperation).

In the PRIOR ART design shown in FIG. 1 , the fasteners 22 arepositioned both above and below the motor 18 and the motor housing 20.In that way, the fasteners 22 extend around the motor 18 and the motorhousing 20 (without passing through any component of the motor 18 or themotor housing 20).

The halves 14, 16 are sized to allow the fasteners 22 to extend aroundthe motor 18 and the motor housing 20 when the tool 10 is assembled, assuggested by PRIOR ART FIG. 1 . Due to the size of the halves 14, 16,the size of the housing 12 may be undesirable in certain situations,such as when space constraints impeding the use of the tool 10 arepresent. Alternatives that enable the size of housing 12, and thus thepackage size of the power tool 10, to be reduced would therefore bebeneficial in such situations.

Referring now to FIG. 2 and FIG. 6 , an illustrative power tool 110according to the present disclosure is shown. Like the power tool 10 ofPRIOR ART FIG. 1 , the power tool 110 shown in FIG. 2 is illustrativelyembodied as a cordless, electric impact tool (in particular, anelectric, pistol-style impact tool). In various embodiments, the powertool 110 may be embodied as a pistol-grip impact tool, an in-line impacttool, or an angle impact tool, such as a right-angle impact tool. Thepower tool 110 includes an impact mechanism 112 that is operable todrive rotation of an output drive 114 (shown in FIG. 6 ) of the powertool 110 about an axis 116 (shown in FIG. 6 ), as best seen in thecross-sectional side view of FIG. 6 . It should be appreciated, however,that in other embodiments, the power tool 110 may be embodied as anelectric power tool that does not include an impact mechanism, such as acorded or cordless electric drill, driver, or ratchet.

The illustrative power tool 110 includes a tool housing 118 that isbroken away to show that the power tool 110 also includes a motorhousing 120 and fasteners 122, as best seen in FIG. 2 . In contrast tothe PRIOR ART power tool 10 of FIG. 1 , the tool housing 118 of the tool110 is not assembled separately from the motor housing 120 of the tool110. Rather, the fasteners 122 are used to secure components of both thetool housing 118 and the motor housing 120 together, such that the motorhousing 120 is supported by the tool housing 118.

The tool housing 118 includes a hammer case 152, a body 126, and a backcap 128, as shown in FIG. 2 . The body 126 defines an interior space 130in which the motor housing 120 is positioned and through which thefasteners 122 extend when the tool 110 is assembled. The hammer case 152is coupled to the body 126, when the tool 110 is assembled, to close offthe interior space 130 and define an output end 134 (shown in FIG. 6 )of the tool 110. The hammer case 152 is formed to include threadedrecesses 170 that receive the threaded ends of the fasteners 122 whenthe tool 110 is assembled. As such, the hammer case 152 may beconsidered a “front housing” or “front cap” of the tool housing 118. Inthe illustrative embodiment, the hammer case 152 supports the impactmechanism 112 of the tool 110. The back cap 128 is also coupled to thebody 126, when the tool 110 is assembled, to close off the interiorspace 130 and define a back end 132 that is positioned opposite theoutput end 134 (shown in FIG. 6 ) of the tool 110. The back cap 128 isformed to include apertures 136 that extend through the back cap 128 andopen into the interior space 130 when the tool 110 is assembled. Theseapertures 136 are sized to receive the fasteners 122 as shown in FIG. 2.

The body 126 is illustratively formed from two mirror-image halves 126A,126B, only one of which is shown in FIG. 2 . It should be appreciated,however, that in other embodiments, the body 126 may be formed from asingle piece or from more than two pieces. The halves 126A, 126B extenddownwardly from the back cap 128 to define a handle 124 which may begrasped by a user of the power tool 110. The halves 126A, 126B eachextend between the hammer case 152 and the back cap 128, such that thebody 126 supports the motor housing 120 when the tool 110 is assembled,as suggested by FIG. 2 . In the illustrative embodiment, the halves126A, 126B of the body 126 are generally divided along a parting planethat passes through both the handle 124 and the motor housing 120.

Referring now to FIG. 3 and FIG. 2 , the body 126 (shown in FIG. 2 )illustratively includes features 127 that are used to position thehalves 126A, 126B (of the body 126) relative to one another duringassembly of the tool 110. Specifically, each of the halves 126A, 126B isformed to include a respective flange 127A, 127B that is received by oneof a pair of corresponding channels 152A, 152B formed in the hammer case152 of the tool housing 118 (see FIG. 2 ). When the flanges 127A, 127Bare received by the channels 152A, 152B, the halves 126A, 126B areguided toward one another around the motor housing 120 (see FIG. 2 ),thereby minimizing any gap between the halves 126A, 126B andfacilitating engagement of the motor housing 120 (see FIG. 2 ) by thebody 126 (shown in FIG. 2 ) during assembly of the tool 110.

Referring now to FIGS. 4-5 , the features 127 also include projections127C-F that are provided on each of the halves 126A and received by theback cap 128 during assembly of the tool 110. In the illustrativeembodiment, the half 126A includes an upper projection 127C and a lowerprojection 127E, while the half 126B includes an upper projection 127Dand a lower projection 127F. During assembly of the tool 110, the halves126A, 126B are guided toward one another until the projections 127C,127D align with and engage one another and the projections 127E, 127Falign with and engage one another, thereby minimizing any gap betweenthe halves 126A, 126B. Once the projections 127C-F of the halves 126A,126B align with and engage one another, the back cap 128 is engaged withthe halves 126A, 126B so that the projections 127C-F are received byslots 129 formed in the back cap 128 (one of which is shown in FIG. 5 ).

The features 127 therefore facilitate attachment of the halves 126A,126B of the body 126 (shown in FIG. 2 ) to the hammer case 152 and theback cap 128 to minimize any gap existing between the halves 126A, 126Bduring assembly of the tool 110, as shown in FIGS. 3-5 . Once the halves126A, 126B are positioned relative to the hammer case 152 and the backcap 128 as discussed above, the fasteners 122 are used to secure theback cap 128 to the hammer case 152, with the halves 126A, 126Bsandwiched between the back cap 128 and the hammer case 152, to assemblethe tool housing 118 of the tool 110.

Referring again to FIG. 2 , the motor housing 120 includes an end bell138 that abuts the back cap 128 and an end bell 140 that abuts thehammer case 152 when the tool 110 is assembled. The end bell 140 isadjacent a transmission 160 of the power tool 110 that extends betweenthe end bell 140 and the impact mechanism 112, as best seen in FIG. 6 .The end bells 138, 140 cooperatively support a rotor 156 and a stator148 of a motor 142 of the tool 110. The end bell 138 is formed toinclude grooves 144 that extend through the end bell 138 parallel to theaxis 116. Likewise, the end bell 140 is formed to include grooves 146that extend through the end bell 140 parallel to the axis 116. When thetool 110 is assembled as shown in FIG. 2 , the grooves 144 of the endbell 138 are aligned with the grooves 146 of the end bell 140, both ofwhich are aligned with the apertures 136 of the back cap 128 and withthe recesses 170 formed in the hammer case 152.

The end bell 138 of the motor housing 120 and the back cap 128 of thetool housing 118 are illustratively separate components as shown in, anddescribed above with reference to, FIG. 2 . It should be appreciated,however, that in other embodiments, the end bell 138 and the back cap128 may be provided as a unitary or integral component. In other words,in some embodiments, the same component may serve as both the end bell138 of the motor housing 120 and the back cap 128 of the tool housing118.

The motor 142 is illustratively embodied as an electric motor, assuggested by FIG. 2 . The motor 142 includes a stationary component,i.e., the stator 148, that is positioned between the end bells 138, 140.The motor 142 also includes the rotor 156 which is configured to rotateabout the axis 116 to drive rotation of the output drive 114 (via thetransmission 160 and the impact mechanism 112). The stator 148 mayfurther define channels that extend through the stator 148 parallel tothe axis 116. When the tool 110 is assembled as shown in FIGS. 2 and 6 ,the channels of the stator 148 are aligned with the grooves 144, 146 ofthe end bells 138, 140, with the apertures 136 of the back cap 128, andwith the recesses 170 formed in the hammer case 152.

Referring now to FIGS. 2 and 6 , the hammer case 152 of the impactmechanism 112 supports a hammer 151 of the impact mechanism 112. Asnoted above, the hammer case 152 is formed to include threaded recesses170 that each receives a threaded end of one of the fasteners 122. Theserecesses 170 each extend parallel to the axis 116, as best seen in FIG.6 . When the tool 110 is assembled as shown in FIGS. 2 and 6 , therecesses 170 of the hammer case 152 are aligned with the grooves 144,146 of the end bells 138, 140, and the apertures 136 of the back cap128.

The fasteners 122 are inserted through the apertures 136, the grooves144, and the grooves 146, and into the recesses 170 when the tool 110 isassembled, as shown in FIGS. 2 and 6. The fasteners 122 secure the backcap 128 to the hammer case 152, with the body 126 sandwiched between theback cap 128 and hammer case 152, to form the tool housing 118.Additionally, the fasteners 122 secure the end bells 138, 140 around thestator 148 to form the motor housing 120. In that way, the fasteners 122secure the tool housing 118 and the motor housing 120 together so thatthe motor housing 120 is supported by the tool housing 118.

The fasteners 122 illustratively extend in a direction indicated byarrow C that is parallel to a direction indicated by arrow D in whichthe motor 142 and the motor housing 120 extend, as shown in FIGS. 2 and6 . The fasteners 122 engage the back cap 128 and extend therefromthrough the interior space 130 to the hammer case 152. The fasteners 122illustratively include four fasteners in the embodiment of FIGS. 2-6 .It should be appreciated, however, that in other embodiments, more orless than four fasteners may be used. Additionally, it should beappreciated that, in some embodiments, fasteners may not be used at all.Rather, clips or metal tie straps, or the like, may be used.

In one respect, because the fasteners 122 extend through the motor 142and the motor housing 120, rather than around the motor 142 and themotor housing 120, the package size of the power tool 110 may be smallerthan the package size of the power tool 10. In another respect, becausethe motor housing 120 and the tool housing 118 are secured together viaone set of fasteners 122, the separate components used to secure thetool housing 12 and the motor housing 20 together may be avoided, andthus the package size of the power tool 110 may be smaller than thepackage size of the power tool 10.

While certain illustrative embodiments have been described in detail inthe figures and the foregoing description, such an illustration anddescription is to be considered as exemplary and not restrictive incharacter, it being understood that only illustrative embodiments havebeen shown and described and that all changes and modifications thatcome within the spirit of the disclosure are desired to be protected.There are a plurality of advantages of the present disclosure arisingfrom the various features of the apparatus, systems, and methodsdescribed herein. It will be noted that alternative embodiments of theapparatus, systems, and methods of the present disclosure may notinclude all of the features described yet still benefit from at leastsome of the advantages of such features. Those of ordinary skill in theart may readily devise their own implementations of the apparatus,systems, and methods that incorporate one or more of the features of thepresent disclosure.

The invention claimed is:
 1. A power tool comprising: a front housing; aback cap opposite the front housing, the back cap defining a pluralityof apertures; a motor assembly between the front housing and the backcap, the motor assembly including: a first end bell, a second end bellopposite the first end bell, and an electric motor between the first endbell and the second end bell, the electric motor having a motor axis, atleast one of the first end bell or the second end bell including aplurality of grooves that extends substantially parallel to the motoraxis, each one of the plurality of grooves open outwardly at acircumferential periphery of the at least one of the first end bell orthe second end bell; and a plurality of fasteners, each one of theplurality of fasteners extending substantially parallel to the motoraxis, through at least one aperture of the plurality of apertures of theback cap, through at least one groove of the plurality of grooves of theat least one of the first end bell or the second end bell, and into thefront housing to connect the front housing, the first end bell, thesecond end bell, and the back cap together.
 2. The power tool as recitedin claim 1, wherein the front housing comprises a plurality of threadedrecesses, each one of the plurality of threaded recesses aligned with agroove of the plurality of grooves of the at least one of the first endbell or the second end bell and configured to receive a fastener of theplurality of fasteners.
 3. The power tool as recited in claim 1, furthercomprising a body around at least a portion of the motor assemblybetween the front housing and the back cap.
 4. The power tool as recitedin claim 3, wherein the body defines an interior space in which themotor assembly is positioned and through which the plurality offasteners extends.
 5. The power tool as recited in claim 3, wherein thebody comprises a first part and a second part, each one of the firstpart and the second part of the body disposed around the at least theportion of the motor assembly between the front housing and the backcap.
 6. The power tool as recited in claim 3, wherein the body comprisesa flange that engages the front housing.
 7. The power tool as recited inclaim 3, wherein the body comprises a flange that engages the back cap.8. A power tool comprising: a front housing; a back cap opposite thefront housing, the back cap defining a plurality of apertures; a motorassembly between the front housing and the back cap, the motor assemblyincluding: a first end bell including a plurality of grooves that eachopen outwardly at a circumferential periphery of the first end bell, asecond end bell opposite the first end bell and including a plurality ofgrooves that each open outwardly at a circumferential periphery of thesecond end bell, and an electric motor between the first end bell andthe second end bell, the electric motor having a motor axis, theplurality of grooves of the first end bell and the plurality of groovesof the second end bell extending substantially parallel to the motoraxis; and a plurality of fasteners, each one of the plurality offasteners extending substantially parallel to the motor axis, through atleast one aperture of the plurality of apertures of the back cap,through at least one groove of the plurality of grooves of the first endbell, through at least one groove of the plurality of grooves of thesecond end bell, and into the front housing to connect the fronthousing, the first end bell, the second end bell, and the back captogether.
 9. The power tool as recited in claim 8, wherein the fronthousing comprises a plurality of threaded recesses, each one of theplurality of threaded recesses aligned with a groove of the plurality ofgrooves of at least one of the first end bell or the second end bell andconfigured to receive a fastener of the plurality of fasteners.
 10. Thepower tool as recited in claim 8, further comprising a body around atleast a portion of the motor assembly between the front housing and theback cap.
 11. The power tool as recited in claim 10, wherein the bodydefines an interior space in which the motor assembly is positioned andthrough which the plurality of fasteners extends.
 12. The power tool asrecited in claim 10, wherein the body comprises a first part and asecond part, each one of the first part and the second part of the bodydisposed around the at least the portion of the motor assembly betweenthe front housing and the back cap.
 13. The power tool as recited inclaim 10, wherein the body comprises a flange that engages the fronthousing.
 14. The power tool as recited in claim 10, wherein the bodycomprises a flange that engages the back cap.
 15. A power toolcomprising: a motor assembly including: a first end bell, a second endbell opposite the first end bell, and an electric motor between thefirst end bell and the second end bell, the electric motor having amotor axis, at least one of the first end bell or the second end bellincluding a plurality of grooves that extends substantially parallel tothe motor axis, each one of the plurality of grooves open outwardly at acircumferential periphery of the at least one of the first end bell orthe second end bell; and a plurality of fasteners, each one of theplurality of fasteners extending substantially parallel to the motoraxis and through at least one groove of the plurality of grooves of theat least one of the first end bell or the second end bell to connect thefirst end bell and the second end bell together.
 16. The power tool asrecited in claim 15, further comprising a front housing and a back capat opposing ends of the motor assembly, and a body around at least aportion of the motor assembly between the front housing and the backcap, the body defining an interior space in which the motor assembly ispositioned and through which the plurality of fasteners extends.
 17. Thepower tool as recited in claim 16, wherein the body comprises a firstpart and a second part, each one of the first part and the second partof the body disposed around the at least the portion of the motorassembly between the front housing and the back cap.
 18. The power toolas recited in claim 16, wherein the body comprises a flange that engagesat least one of the front housing or the back cap.